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3-D Reliable, High Power Density, Fast-Recharge Battery

The Product

A small, lightweight lithium-ion battery characterized by an unprecedented power density, capable of charging and discharging power rapidly over an extended lifetime while exhibiting dramatically low capacity loss over thousands of cycles.

The Market

Since their introduction in 1990 by Sony Corporation, lithium-ion batteries have experienced rapid growth and worldwide market penetration. The major application areas of lithium-ion batteries are in consumer electronics (especially mobile IT, communication and audio/video devices), industrial applications (military, health care and heavy-duty cordless tools) and high-powered applications within the automotive, aerospace and defense sectors. The global market is extremely large and growing rapidly. Currently estimated to be $7B, it is expected to surpass $10B within 3-4 years.

The Technology

Today’s growing need for energy storage as related to renewables, electric/hybrid vehicles, consumer products, and government applications drives the requirement for a radical change in battery design and production. In order to achieve such critical requirements in lithium battery performance, researchers in the Department of Chemistry at Colorado State University have designed a revolutionary battery architecture intended to address the slow diffusion of lithium ions (Li+) into and between the anode and cathode. This patent-pending architecture is designed around a nanowire array of anodes, conformally coated by an ultra-thin polymer electrolyte and then surrounded by a cathode matrix. The result is a three-dimensionally structured lithium-ion battery composed of interpenetrating, nanometer scale electrodes with extremely short Li+ diffusion distances and a power density that is orders of magnitude greater than comparable two-dimensional architectures in use today, and under development for future applications. Furthermore, the use of copper antimonide (Cu₂Sb) nanowires lends an unprecedented degree of stability to the anode and has already demonstrated virtually no loss of capacity over extensive cycling – a dramatic improvement over other anode materials. Such materials, and the underlying technologies described herein readily lend themselves to low cost manufacturing and production scale-up.

The realization of this sophisticated battery required the development of myriad cutting-edge enabling technologies. At the heart of this product is a patent-pending technology for the fabrication of the Cu₂Sb nanowires. Using a novel electrodeposition method, Cu₂Sb may be directly deposited as polycrystalline, intermetallic nanowires without the costly requirement of further annealing or other post-treatments. Additionally, this technique ensures continuous electrical contact throughout the 3D anode. Similarly, the fabrication of the electrolyte layer is accomplished through an electrochemical polymerization method – specifically designed to uniformly encapsulate the entire conductive surface of the anode. The electrolyte is kept extremely thin to allow for the subsequent interpenetration into the structure by the cathode material and is anticipated to be extraordinarily insulating and pin-hole free. The strict demands on the electrolyte form the basis for additional intellectual property protection.